An immersion heater is a device which is installed in a tank or container to heat a liquid. The installation can be over-the-side, flanged or threaded.
Over-the-Side Immersion HeatersOver-the-side immersion heaters are designed for vessels where through the side immersion heaters cannot be conveniently installed. These heaters are installed through the top of the vessel with the heated portion of the unit along the side or at the bottom of the tank. Natural circulation of the fluid inside the vessel allows for even distribution. Terminal houses or lead wires are provided for power connection.
These industrial heaters are available with heating elements made of copper, steel, stainless steel, cast iron, Incoloy, titanium, and PFA coated. A wide selection of kilowatt ratings, shapes and mounting methods are available to suit many different types of applications.
The large variation in heating element material and shapes of over-the-side immersion heaters offers a wide selection in the application of these units. Water, oils, solvent, plating baths, salts and acids are some of the many liquids and viscous materials commonly heated with immersion heaters. Over-the-side types permit portability, easy removal for cleaning of tanks and heaters, and ample working area within the tank when installed.
Flanged Immersion HeatersFlanged immersion heaters consist of hairpin bent tubular elements welded or brazed into a flange and provided with wiring boxes for electrical connections. Flange heaters are installed by bolting to a matching flange welded to the tank wall or nozzle. A wide selection of flange sizes, kilowatt ratings, voltages, terminal housings and sheath materials makes these heaters ideal for all types of heating applications.
Flanged immersion heaters are one of the most widely used methods for heating liquids (such as water, oil, heat transfer fluid and corrosive solutions). Designed for use in tanks and pressurized vessels, they are easy to install and maintain to provide heat for many processes. The direct immersion method is energy efficient and easily monitored and controlled.
These through-the-side immersion heaters utilize standard pipe flanges ranging from 3" to 14" in diameter to support high tank pressures of liquids. They are installed through a matching companion flange, obtainable from local industrial supply houses, to the tank wall. A wide selection of watt densities, heating outputs and flange sizes and ratings make this an excellent heater for all tanks, vats or irregularly shaped vessels.
Threaded or Screw Plug Immersion HeatersScrew plug immersion heaters consist of hairpin bent tubular elements brazed or welded into a screw plug and provided with wiring boxes for electrical connections. Screw plug immersion heaters are screwed directly through a threaded opening in a tank wall or through matching pipe coupling, half coupling or welding flange. Sizes of screw plug heaters are available with ½", ¾", 1", 1¼", 2" and 2½" pipe threads. A wide selection of screw plug sizes, kilowatt ratings, voltages, sheath materials, terminal housings, and thermostats makes these compact heaters ideal for all types of applications.
Screw plug immersion heaters are used for heating liquids in a variety of processes. Those heaters are ideal for process water heating and freeze protection. All types of oils and heat transfer solutions can also be heated using these compact easily controlled units. The direct immersion method is energy efficient and well suited for many applications.
Choose the right Immersion Heater for your application
Screw Plug Immersion Heaters
A screw plug immersion heater can be applied to a variety of clean water and oil applications. The unique versatility of this design allows field adjustment of the rating by simple connections to the six elements of the heater. This simplifies selection and spare parts since each heater may be used in several different heating applications.
Screw Plug Immersion Heaters with Single Thread Pipe Construction
The screw plug immersion heaters with single thread pipe construction is a compact device for with either 5/8", ¾" or 1¼" diameter 316 SS sheaths. The immersion heaters have ratings of 400 to 1000 Watts. Screw plug immersion heaters can be applied to a variety of clean water and oil applications.
Flanged Immersion Heaters
The flanged immersion heater features a rugged construction. Heavy duty jumper straps and terminal parts assure permanent tightness of connections. The outer sheath provides the benefits of strength and durability featuring a long life elements.
Over-the Side Immersion Heaters
The PTH Series consists of a heavy-duty, general purpose heater for plating tanks, rinse tanks, and other tanks containing aqueous solutions. The 316 SS sheath is passivated, providing resistance to corrosion. These heaters are equipped with a vapor-tight terminal enclosure and a 3-foot-long, vinyl-covered flexible conduit containing the 2 power leads and a ground wire. The stainless steel mounting bracket can slide along the element, which makes installation easy. screw plug immersion heaters.
Portable Tank Heaters
The CH-OTS heater series is a easy-to-use and simple-to-install portable tank heater. The heater consists of copper sheath Nickel plated elements, watt densities in the range of 40 to 50 W/in2, power ratings of 4 and 6 kW for 208 and 240 Volt. The main features of the heater include a 26 inch riser (unheated section) and an integrated temperature control for the range of 60 to 250F.
Frequently Asked Questions
Thermostats or Temperature Control
Many screw plug and flanged type heaters are available with built-in thermostatic controls. In some installations, where there is more than one heater in a tank, you may consider one heater with a built-in control that will control the other heaters by wiring thermostat into the holding coil circuit of a magnetic contactor. If the thermostat is separate from the heater, the thermostat sensing element should be located approximately 4 to 6 inches above the heater. Other types of controls are available where a high degree of accuracy or a more versatile control scheme is required. Electronic controls and complete control panels are easily installed.
How does an Immersion Heater Work?
Immersion heaters are made by encasing a resistance heating wire in a ceramic jacket which is then surrounded by a sheath. The sheath can be made of copper, steel, stainless steel, cast iron, incoloy, titanium, or PFA coated. As electricity flows through the heating element, it moves heat at a high rate through the ceramic jacket and sheath. The heat emanating from the sheath quickly heats the water or liquid surrounding it.
What are the Operating Temperatures of an Immersion Heater?
Immersion heaters are available in many temperature ranges. The temperature an immersion heater can output depends on the supply voltage and the resistance (watts = voltage2/resistance). Industrial heaters can typically heat water to around 900°F (482°C) internally. The heat output will remain constant regardless of the environment or application since the heater’s resistance measurement is also constant.
What are the Applications of an Immersion Heater?
Each type of immersion heater is suited for different types of applications. Water, oils, solvent, plating baths, salts, and acids are some of the many liquids and viscous materials commonly heated with immersion heaters.
Below are the most common applications for the different types of immersion heaters:
- Over-the-side immersion heaters are best for applications where ample working area and portability, such as for easy removal for cleaning of tanks and heaters, is important.
- Flanged immersion heaters are excellent heater choice for all tanks, vats, or irregularly shaped vessels due to the wide selection of watt densities, heating outputs, and flange sizes and ratings of these heaters.
- Screw plug immersion heaters are ideal for process water heating and freeze protection. All types of oils and heat transfer solutions can also be heated using these compact and easily controlled units. The direct immersion method is energy efficient and well suited for many applications.